Inflatable packaging with tear initiation feature

ABSTRACT

An inflatable web is disclosed. The web includes first and second film plies sealed together via a plurality of generally transverse seals to define a first and second inflatable chambers and an inflation region. The chambers are inflatable with a fluid and operable to contain the fluid. The sealed plies have a first longitudinal edge and a second longitudinal edge. The web defines a separation region extending at least partially transversely across the web between the first and second inflatable chambers and is configured to facilitate separation thereof. The separation region includes a tear propagation line extending transversely across at least a portion of the web with an end of the tear propagation line terminating proximal to the first longitudinal edge of the web. The separation region includes a tear initiation feature including edges spaced apart from one another longitudinally to form a permanent opening in the web.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority pursuant to 35 U.S.C. §119(e) of U.S. provisional patent application nos. 62/718,385 filed 14Aug. 2018, entitled “INFLATABLE PACKAGING WITH TEAR INITIATION”;62/723,396 filed 27 Aug. 2018, entitled “INFLATABLE PACKAGING WITH TEARINITIATION”; 62/803,197 filed 8 Feb. 2019, entitled “INFLATABLEPACKAGING WITH TEAR INITIATION”; and 62/849,628 filed 17 May 2019,entitled “INFLATABLE PACKAGING WITH TEAR INITIATION”, each of which ishereby incorporated by reference herein in their entireties for allpurposes. This application is also copending with patent applicationSer. No. 16/541,082 filed 14 Aug. 2019, entitled “INFLATABLE PACKAGINGWITH OFFSET TEAR INITIATION FEATURES”, which is hereby incorporated byreference herein in its entirety for all purposes.

FIELD OF THE INVENTION

The present invention relates generally to inflatable cushioningmaterial for packaging and shipping, and more specifically, to segmentedinflatable material with easily removable segments.

SUMMARY

An inflatable web is disclosed. The web includes a first film ply and asecond film ply sealed to the first ply via a plurality of generallytransverse seals. The plurality of transverse seals define first andsecond inflatable chambers therebetween. The inflatable chambers areinflatable with a fluid and operable to contain the fluid. The sealedplies having a first longitudinal edge and a second longitudinal edge.In accordance with various embodiments, the web defines a separationregion extending at least partially transversely across the web betweenthe first inflatable chamber and the inflatable second chamber. Theseparation region is configured to facilitate separation of the firstand second inflatable chambers. In various embodiments, the separationregion includes a tear propagation line extending transversally acrossat least a portion of the web. An end of the tear propagation lineterminates proximal to the first longitudinal edge of the web or theinflation region. The separation region includes a tear initiationfeature including edges spaced apart from one another longitudinally toform a permanent opening in the web, and close enough to the tearpropagation line that a force imparted to the web via the tearinitiation feature will facilitate the initiation of a tear of the websuch that the tear propagates to an end of the tear propagation line andallowing for the tearing of the web to separate the first inflatablechamber from the second inflatable chamber.

In accordance with various embodiments, the tear propagation lineincludes a first line of weakness extending transversely across aportion of the web. The tear initiation feature is configured tofacilitate the engagement between a user and the web for tearing. Thetear initiation feature is suitable for a user to grasp the web byextending one of a hand, finger, or tool, through the web. The tearpropagation line includes a second line of weakness extendingtransversely across at least a portion of the web with an end of thesecond line of weakness line terminating proximal to the secondlongitudinal edge of the web. The tear initiation feature is disposedbetween respective ends of the first line of weakness and the secondline of weakness.

In accordance with various embodiments, respective lands are disposedbetween respective ends of the tear initiation feature and the first andsecond lines of weakness. Additionally or alternatively, the first lineof weakness includes a line of perforations through at least one of thefirst ply or second ply. Additionally or alternatively, the second lineof weakness includes a line of perforations through at least one of thefirst ply or second ply. The tear initiation feature is transverselyoffset from both the first and second longitudinal edges. The tearinitiation feature is in a generally central position relative to thetransverse width of the web.

In accordance with various embodiments, the tear propagation line andthe tear initiation feature are sufficiently close that a tear initiatedin the tear initiation feature propagates to the tear propagation line.The tear initiated in the tear initiation feature propagates to the tearpropagation line to completely separate the first chamber from thesecond chamber. The first line of weakness extends transversely acrossthe web from the first longitudinal edge to the second longitudinaledge. The tear initiation feature is longitudinally offset from thefirst line of weakness and the second line of weakness. The tearinitiation feature includes a pair of openings through the web and theopenings are transversely offset from one another. The tear initiationfeature includes a third line of weakness extending transversely acrossa portion of the web, and the third line of weakness is longitudinallyoffset from the pair of openings. The perforations of the third line ofweakness are transversely larger than the perforations of the first lineof weakness and the second line of weakness.

BACKGROUND

Products and packages can be produced and/or shipped in a variety ofcontainers and configurations for transportation and sale. Variouspackaging materials exist to protect the products and packages frombeing crushed or damaged during transportation. Such packaging materialsform a protective outer layer over the products and packages andotherwise maintain the form factor of the products and packages withinthe shipping container. The packaging material can be wrapped one ormore times around the products or packages or placed within empty spaceswithin the container. In this manner, the packaging material can besized according to the size of the products or packages.

Inflatable packaging is a type of packaging material used to protectproducts and packages during transportation. This packaging material canbe segmented to allow a user to select a particular number of inflatablesegments based on the size of the product or package. The inflatablesegments can be separated by a single tear strip, which allows a user toeasily separate segments. Often, due to the nature of these single tearstrips (e.g., a slit within the tear strip), a tear can initiateunintentionally. There is a need for a more efficient tearing mechanism.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features of the present disclosure will becomemore fully apparent from the following description and appended claims,taken in conjunction with the accompanying drawings. Understanding thatthese drawings depict only several examples in accordance with thedisclosure and are, therefore, not to be considered limiting of itsscope, the disclosure will be described with additional specificity anddetail through use of the accompanying drawings, in which:

FIG. 1 is a schematic of a flexible structure for use with an inflationand sealing device;

FIG. 2 is a schematic of a separation region usable in conjunction withthe flexible structure of FIG. 1, in accordance with one embodiment;

FIG. 3 is a schematic of a separation region usable in conjunction withthe flexible structure of FIG. 1, in accordance with one embodiment;

FIG. 4 is a schematic of a separation region usable in conjunction withthe flexible structure of FIG. 1, in accordance with one embodiment;

FIG. 5 is a schematic of a separation region usable in conjunction withthe flexible structure of FIG. 1, in accordance with one embodiment; and

FIG. 6 is a schematic of a separation region usable in conjunction withthe flexible structure of FIG. 1, in accordance with one embodiment;

FIG. 7A is a schematic of a separation region usable in conjunction withthe flexible structure of FIG. 1, in accordance with one embodiment;

FIG. 7B is a detail view of the separation region of FIG. 7A;

FIG. 8A is a schematic of a separation region usable in conjunction withthe flexible structure of FIG. 1, in accordance with one embodiment;

FIG. 8B is a detail view of the separation region of FIG. 8A;

FIG. 9 is a schematic of a separation region usable in conjunction withthe flexible structure of FIG. 1, in accordance with one embodiment;

FIG. 10 is a schematic of a separation region usable in conjunction withthe flexible structure of FIG. 1, in accordance with one embodiment;

FIG. 11 is a schematic of a separation region usable in conjunction withthe flexible structure of FIG. 1, in accordance with one embodiment;

FIG. 12A is an isometric view of a stamping machine for creatingseparation regions in a web according embodiments of the presentdisclosure;

FIG. 12B is a partial detail view of a portion of the machine of FIG.12A;

FIG. 13 is a schematic view of a stamping machine for creatingseparation regions in a web according to embodiments of the presentdisclosure;

FIG. 14 is an isometric view of an inflation machine for inflatinginflatable chambers of a web according to embodiments of the presentdisclosure;

all arranged in accordance with at least some embodiments of the presentdisclosure.

DETAILED DESCRIPTION

The present disclosure is directed to flexible structures that can beinflated and used as cushioning or protection for packaging andshipping. In the following detailed description, reference is made tothe accompanying drawings, which form a part hereof. In the drawings,similar symbols typically identify similar components, unless contextdictates otherwise. The illustrative examples described in the detaileddescription, drawings, and claims are not meant to be limiting. Otherexamples can be utilized, and other changes can be made, withoutdeparting from the spirit or scope of the subject matter presentedherein. It will be readily understood that the aspects of the presentdisclosure, as generally described herein and illustrated in thefigures, can be arranged, substituted, combined, separated, and designedin a wide variety of different configurations, all of which areimplicitly contemplated herein.

As shown in FIG. 1, this disclosure is drawn, inter alia, to methods,systems, products, devices, and/or apparatus generally related toflexible structures. The flexible structure, such as a multi-ply web 100of film, for inflatable cushions is provided. The web 100 includes afirst web film layer, or ply, 105 having a first longitudinal edge 102and a second longitudinal edge 104, and a second web film layer, or ply,107 having a first longitudinal edge 106 and a second longitudinal edge108. The longitudinal edges 102, 104, 106, 108 run in a longitudinaldirection 103 of the web 100. The longitudinal direction of the web canbe the direction that the web 100 is advanced into a processing machine.The longitudinal direction 103 can also be the direction that the web100 is unrolled to be fed into a processing machine, or the directionthat the finished structure is rolled onto a storage roll afterprocessing. A longitudinal direction 103 can be longitudinally upstreamor longitudinally downstream. A longitudinally upstream direction 109 isa longitudinal direction opposed to a direction of movement of the web100 through a processing machine. A longitudinally downstream direction111 is a direction that is substantially the same as a direction of theweb 100 through a processing machine. Generally, a longitudinaldirection 103 corresponds to the longest dimension of the web filmlayers 105,107. The second ply 107 is aligned to be overlapping and canbe generally coextensive with the first ply 105 (as shown in FIG. 1),i.e., at least respective first longitudinal edges 102, 106 are alignedwith each other and/or second longitudinal edges 104, 108 are alignedwith each other. In some embodiments, the layers, or plies 105, 107, canbe partially overlapping with inflatable areas in the region of overlap.The plies 105, 107 can be joined to define a first longitudinal edge 110and a second longitudinal edge 112 of the film 100. A longitudinal seal113 can be formed at the edge 110, and a longitudinal seal 115 can beformed at the edge 112. For example, the first longitudinal edges 102,106 can be coupled together to form the first longitudinal edge of thefilm 100 and the second longitudinal edges 104, 108 can be coupledtogether to form the second longitudinal edge 112 of the film 100. Thecoupling of the respective edges forms an airtight seal at the first andsecond longitudinal edges 110, 112 of the film 100. The first and secondplies 105, 107 can be formed from a single sheet of web material, aflattened tube (such as tube formed by blow molding) of web materialwith one edge slit, or two sheets of web material. For example, thefirst and second plies 105, 107 can include a single sheet of webmaterial that is folded to define the joined second edges 104, 108(e.g., “c-fold film”). Alternatively, for example, the first and secondplies 105, 107 can include a tube of web material (e.g., a flattenedtube) that is slit along the aligned first longitudinal edges 102, 106.Further, for example, the first and second plies 105, 107 can includetwo independent sheets of web material joined, sealed, welded, adhered,or otherwise attached together along the aligned second edges 104, 108.

The web 100 can be formed from any of a variety of web materials knownto those of ordinary skill in the art. Such web materials may includeethylene vinyl acetates (EVAs), metallocenes, polyethylene resins suchas low density polyethylene (LDPE), linear low density polyethylene(LLDPE), and high density polyethylene (HDPE), and blends thereof. Othermaterials and constructions can be used. The disclosed web 100 can berolled on a hollow tube, a solid core, or folded in a fan folded box, orin another desired form for storage and shipment.

As shown in FIG. 1, the web 100 included a series of transverse seals118 disposed along the longitudinal extent of the web 100 in atransverse direction. A transverse direction is a direction extending atan angle to a longitudinal direction of the web 100. In someembodiments, the transverse direction is substantially perpendicular tothe longitudinal direction. However, in other embodiments, a transversedirection can be at a non-perpendicular angle to the longitudinaldirection, more than zero degrees and less than 90 degrees. A transverseseal 118 can extend in multiple transverse directions, such as azig-zag, wave, undulating line, chevron, or other pattern. Eachtransverse seal 118 extends from the second longitudinal edge 112 towardthe first longitudinal edge 110. The transverse seal 118 can extendtoward an inflation channel 114, discussed in more detail below. Eachtransverse seal 118 has a first end 122 proximate the secondlongitudinal edge 112 of the film 100 and a second end 124 proximate thefirst longitudinal edge 110 of the film 100. The second end 124 can bespaced a transverse dimension D from the first longitudinal edge 110.The distance between the first end 122 and second end 124 defines thetransverse width t of the transverse seal 118. Each transverse seal 118embodied in FIG. 1 is substantially straight and extends substantiallyperpendicular to the second longitudinal edge 112 (e.g., transverselyacross the film 100). It is appreciated, however, that otherarrangements of the transverse seals 118 are also possible. For example,in some embodiments, the transverse seals 118 have undulating patternsor zigzag patterns, or similar suitable designs. The transverse seals118 as well as the sealed longitudinal edges 110, 112 can be formed fromany of a variety of techniques known to those of ordinary skill in theart. Such techniques include, but are not limited to, adhesion,friction, welding, fusion, heat sealing, laser sealing, and ultrasonicwelding. It is contemplated that the transverse seal 118 can be sealedalong the entirety of its area (its traverse width t and longitudinalheight L); however, it is also contemplated that the transverse seal canbe sealed around a periphery with its middle portion unsealed, forming apocket in its middle portion. For example, some embodiments transverseseals 118 can include unsealed areas such as rectangles, squares,circles, ovals, or other shapes within the seal area. It is alsocontemplated that the transverse seals 118 can be sealed with alongitudinal seal 113 proximate to the second ends 124. In otherembodiments, a pair of substantially linear seals 118 can be disposed oneither side of a separation region 126.

An inflatable chamber 120 is defined within a boundary formed by thesecond longitudinal edge 112 and a pair of adjacent transverse seals118, such that the inflatable chambers 120 are sufficiently bounded tobe inflatable by and contain a fluid when sealed. Suitable fluids can begases such as air, carbon dioxide, nitrogen, or other suitable gases.Fluids can also be liquids or gels. When the inflatable chamber 120 isfilled with a fluid, the web film layers, such as plies 105,107 aremaintained apart from one another when the chamber is sealed, to providecushioning. As shown in FIG. 1, a plurality of inflatable chambers 120are positioned adjacent to one another along the longitudinal length ofthe web 100 forming inflatable segments 120 of the web 100. In someembodiments, the inflatable chambers can further include one or moreinterior seals. For example, the interior seals can seal the plies 105,107 to one another at intermediate areas within the chamber 120. Theinterior seals can create bendable lines that allow for a more flexibleweb 100 that can be easily bent or folded. Such flexibility allows forthe film 100 to wrap around regular and irregular shaped objects.

An inflation region, such as a closed passageway, which can be alongitudinal inflation channel 114, can be provided. The longitudinalinflation channel 114, as shown in FIG. 1, is disposed between thesecond end 124 of the transverse seals 118 and the first longitudinaledge 110 of the film 100. The longitudinal inflation channel 114 canextend longitudinally along the longitudinal edge 110 and an inflationopening 116 can be disposed on at least one end of the longitudinalinflation channel 114. The longitudinal inflation channel 114 has atransverse width D. In a preferred embodiment, the transverse width D issubstantially the same distance as the transverse dimension between thefirst longitudinal edge 110 and second end 124. It is appreciated,however, that in other configurations other suitable transverse width Dsizes can be used. In some embodiments, the inflation opening 116includes a one-way valve such as those disclosed in U.S. Pat. No.7,926,507, herein incorporated by reference in its entirety.

In various embodiments, the web 100 includes one or more separationregions 126. The separation region 126 facilitates separation of twoadjacent inflatable chambers 120 such as by tearing the web 100 by handor with the assistance of a tool or machine. A separation region 126 canfacilitate either or both partial or total separation of adjacentinflatable chambers 120. As illustrated in the schematic of FIG. 1, theseparation region 126 is positioned between chambers 120. In this way,chambers 120 can be easily separated from one another. In the embodimentof FIG. 1, thin transverse seals 118 are arranged adjacent to theseparation regions 126, on either side. While illustrated adjacent tothe seal 118, it is appreciated that the separation region 126 can alsoextend through the seal 118, or through unattached plies 105,107 such asthrough the chambers 120. As provided in more detail below in thevarious described embodiments, the separation region 126 can have avariety of configurations that allow a user's hand, finger, tool, orsimilar suitable feature to easily penetrate through the web 100 toinitiate a tear in the web 100. The separation region 126 is disposedbetween adjacent inflatable chambers 120, and can be offset from theadjacent chambers 120 by at least a portion of a transverse seal 118. Asshown in FIG. 1, a separation region 126 can be offset longitudinallyfrom an inflatable chamber 120 with a transverse seal 118 disposedtherebetween.

A tear initiation feature 128 is a region that helps a user tear the web100 to separate adjacent inflatable chambers 120. In some embodiments, atear initiation feature 128 helps a user start a tear in the web 100, byallowing a user to grasp, grip, hold, or pinch a portion of the web 100adjacent to the tear initiation feature 128, such as a hole, handle, oropening suitable for a user to insert a hand, finger, or tool therethrough to grip an edge thereof. In this embodiment, the tear initiationfeature 128 is a secondary opening 129 a extending through portions ofone or both web film layers 105,107 transversely across a portion of theweb 100 that a user can insert a hand, finger, or tool through to grip aportion of the web 100. A tear initiation feature 128 can be a line ofapertures that pierce through one or both web film layers 105,107. Forexample, the apertures can be perforations, slits, openings in the web100. A tear initiation feature 128 can be a line of weakness thatpierces through one web film layer 105, and another line of weaknesslongitudinally offset from the first line of weakness that piercesthrough the other web film layer 107.

A tear propagation line 130 is a line that is sufficiently close to atear initiation feature 128 such that a pulling or tearing forceimparted to the web 100 via a tear initiation feature 128 will cause atear to initiate in the tear propagation line 130 and continue across aportion of the web 100 to separate two adjacent inflatable chambers 120.Also, a tear can initiate in a tear initiation feature 128, such as atthe edges. A tear starting in a tear initiation feature 128 can continueinto and through a tear propagation line 130 to separate adjacentinflatable chambers 120. In this embodiment, the tear propagation lines130 extend from first and second longitudinal edges 102, 104, 106, 108across a portion of the web 100. A tear initiation feature 128 can beweaker than a tear propagation line 130. This allows for an easier starta tear in the web 100 via a tear initiation feature 128, and oncestarted, propagate a tear through the tear propagation line 130 toseparate adjacent inflatable chambers 120.

In accordance with one embodiment, as shown in FIG. 1, the inflatablechambers 120 can be separated by separation regions 126. It should,however, be appreciated that other embodiments, such as those discussedbelow in FIGS. 3-11 are also usable as separation regions 126replaceable with the separation region 126 shown in the web 100 ofFIG. 1. As shown in FIG. 1, the separation region 126 includes a tearinitiation feature 128 and a tear propagation line 130. For example, atear propagation line 130 includes a first line of weakness 127 a andanother tear propagation line 120 includes a second line of weakness 125a. The tear initiation feature 128 includes a secondary opening 129 aextending transversely across a portion of the web 100. While the firstline of weakness 127 a is shown as extending across the inflationchannel 114, denoted by the distance D in FIG. 1, it is appreciated thatthe first line of weakness 127 a can also terminate with the seal 118 ator proximate seal end 124. The perforations forming the lines ofweakness can be smaller than a finger, such as from about 1/32nd of aninch to about ½ inch. Other perforations can be larger than a tip of afinger such as greater than about ½ inch to about 1 inch. Otherperforations can be larger still from about 1 inch to several incheslong.

In accordance with one embodiment, as shown in FIG. 1, the inflatablechambers 120 can be separated by separation regions 126 a usable inconjunction with the web 100 of FIG. 1. As shown, the separation region126 a includes a tear initiation feature 128 and two tear propagationlines 130. A tear initiation feature 128 can cause a tear to initiate inthe adjacent tear propagation lines 130 when a pulling force is appliedto its edges. Force applied to the tear initiation feature 128 can causea tear to start in one of the edges of the tear initiation feature 128.This may happen for example, if the edges of the tear initiation feature128 have sharp bends cuts or other features that act as stress risers toinitiate a tear. Such a tear may then continue on to the tearpropagation lines 130 through the land 132 a that separates the tearinitiation feature 128 from the tear propagation line 130. In theembodiment shown, the tear propagation lines 130 include a first line ofweakness 127 a and a second line of weakness 125 a extendingtransversely across a portion of the web 100. The first line of weakness127 a can be proximate the first longitudinal edge 110, while the secondline of weakness 125 a can be proximate the second longitudinal edge112. While only two lines of weakness are depicted, other numbers oflines of weakness can extend transversely across the web 100. While theline of weakness 127 a is shown as extending across the inflationchannel 114, denoted by the distance D in FIG. 1, it is appreciated thatthe line of weakness 127 a can also terminate with the seal 118 at orproximate seal end 124.

The tear initiation feature 128 includes a secondary opening 129 a. Thesecondary opening 129 a can be any suitable opening, such as a handle,through the web 100 allowing a user to hold onto the web or otherwiseextend a hand, finger, tool, or similar feature through the web 100. Thesecondary opening 129 a can be an aperture through both plies 105,107 ofthe web 100. In other embodiments, a secondary opening can be anaperture through one of the plies 105,107 and not the other. The edgesof the secondary opening 129 a are spaced apart from one anotherlongitudinally to form a permanent opening in the web 100. The plies105,107 can be sealed to one another at the edges in some embodiments.In other embodiments, the plies may not be sealed to one another at theedges. As shown in FIG. 2, the corners of the secondary opening 129 aare relatively sharp and can act as stress risers to help initiatetearing of the web 100. For example, a tear can initiate in a corner ofthe secondary opening 129 a and continue to propagate to the first lineof weakness 127 a and/or the second line of weakness 125 a to separateadjacent inflatable chambers 120. The secondary opening 129 a can be aslit, a perforation, a rectangular or oval-shaped opening, or the like.As shown in FIG. 2, the secondary opening 129 a can be a transverseaperture having both a significant longitudinal distance 135 a and asignificant transverse distance 139 a. The transverse distance 139 a issuch that that a land 132 a is disposed between respective ends of thesecondary opening 129 a and the respective lines of weakness 127 a, 125a. The longitudinal distance 135 a can be less than the transversedistance 139 a of the secondary opening 129 a. In this embodiment, thesecondary opening 129 a extends parallel to the line of weakness 127 aand/or 125 a. As shown, the first line of weakness 127 a extends atransverse distance shorter than the transverse distance 139 a of thesecondary opening 129 a. Additionally or alternatively, the second lineof weakness 125 a extends a transverse distance shorter than thetransverse distance 139 a of the secondary opening 129 a. In someembodiments, the first line of weakness 127 a and the second line ofweakness 125 a are the same length; however, it is contemplated that thelengths of either line of weakness 127 a, 125 a can vary.

FIG. 3 shows an embodiment similar to that of FIG. 2, where thesecondary opening 129 a is longitudinally offset from the lines ofweakness 125 a, 127 a a distance 133 a. In this embodiment, the tearinitiation feature is longitudinally downstream of the tear propagationline 130. In other embodiments, the tear propagation line 130 can belongitudinally downstream of the tear initiation feature 128. The tearinitiation feature 128 and the tear propagation line 130 are parallel toone another. The tear initiation feature 128 is longitudinally adjacentto the tear propagation line 130. The longitudinal offset of the tearinitiation feature 128 from the tear propagation line 130 is such that apulling force imparted to the web 100 via the tear initiation feature128 when a user pulls on the tear initiation feature 128 can cause atear to start or propagate through the tear propagation line 130, toseparate the inflatable chambers 120 adjacent to a given separationregion 126 containing both the tear initiation feature 128 and the tearpropagation line 130

In some examples, the distance 133 a is the same as or less than theconnection distance between perforations in embodiments in which thelines of weakness 125 a, 127 a are perforations (e.g., FIG. 3 shows thelines of weakness 125 a, 127 a as transverse perforations). In otherexamples, the distance 133 a is greater than the connection distancebetween perforations in embodiments in which the lines of weakness 125a, 127 a are perforations. The longitudinal distance 135 a can begreater than the offset 133 a. The distance 133 a can be determined by ashim or plate thickness equal to, greater than, or a multiple of, theknife thickness used for forming the lines of weakness. In someexamples, the distance 133 a is the same as or less than the connectiondistance between perforations in embodiments in which the line ofweakness 127 a is a perforation (e.g., FIG. 1 shows the line of weakness127 a as a transverse perforation).

The tear propagation lines 130, including the first and second lines ofweakness 127 a, 125 a transversely overlap the tear initiation feature128 by a distance 141. Further, it is contemplated that the first lineof weakness 127 a and the second line of weakness 125 a can merge,forming a single line of weakness extending across a portion of thetraverse width or across the entire traverse width of the web 100. Asshown in FIG. 3, an intermediate land 137 a can extend between the firstline of weakness 127 a and the second line of weakness 125 a. The land137 a can be transversely the same length or shorter than the transversedistance 139 a of the secondary opening 129 a. In other embodiments, theland 137 a can be transversely longer than the transverse distance 139 aof the secondary opening 129 a.

In accordance with one embodiment, as shown in FIG. 4, the inflatablechambers 120 can be separated by separation regions 126 b usable inconjunction with the web 100 of FIG. 1. As shown, the separation region126 b includes a tear initiation feature 128 and a tear propagation line130. The tear propagation line 130 includes a first line of weakness 127b, a second line of weakness 123 b. The tear initiation feature 128includes a third line of weakness 125 b extending transversely across aportion of the web 100. The tear initiation feature 128 can have one ormore secondary openings 129 b/152 b. Like the secondary opening 129 a ofthe embodiment of FIG. 2, the secondary openings 129 b, 152 b can havesharp corners or features that act as stress risers to help initiate orpropagate tearing. Other embodiments may have smooth edges withoutstress risers such that tears are not likely to initiate in the openings129 b, 152 b. The secondary openings 129 b, 152 b can be longitudinallyoffset from the first, second, and/or third lines of weakness 127 b, 123b, 125 b a distance 133 b. While the first line of weakness 127 b isshown as extending across the inflation channel 114, denoted by thedistance D in FIG. 1, it is appreciated that the first line of weakness127 b can also terminate with the seal 118 at or proximate seal end 124.The first line of weakness 127 b can extend transversely across the web100 a distance 157 b from the first longitudinal edge 110. The firstline of weakness 127 b can extend from the first longitudinal edge 110in a direction perpendicular to the first longitudinal edge 110. Thesecond line of weakness 123 b can extend across the web 100 a distance155 b from the second longitudinal edge 112. The second line of weakness123 b extends perpendicular to the second longitudinal edge 112. Inother embodiments, the first or second lines of weakness 127 b, 123 bcan extend off-perpendicular to their respective edges 110, 112. Thefirst line of weakness 127 b and/or the second line of weakness 123 bcan be longitudinally offset from the third line of weakness 125 b at adistance 163 b. In some examples, the distance 163 b is the same as orless than the connection distance between perforations in embodiments inwhich the line of weakness 127 b or 123 b is a perforation (e.g., FIG. 4shows the line of weakness 127 b as a transverse perforation). In otherexamples, the distance 163 b is greater than the connection distancebetween perforations in embodiments in which the first line of weakness127 b and the second line of weakness 123 b is a perforation (e.g., therow of holes shown in FIG. 4).

As shown in FIG. 4, the third line of weakness 125 b can have asignificant transverse distance 139 b. The third line of weakness 125 bextends parallel to the first line of weakness 127 b and/or the secondline of weakness 123 b. In some embodiments, the first line of weakness127 b, the second line of weakness 123 b, and the third line of weakness125 b are all co-linear. In other embodiments, the third line ofweakness 125 b is transversely offset from the first longitudinal edge110 a distance 151 b. Additionally or alternately, the third line ofweakness 125 b can be transversely offset from the second longitudinaledge 112 a distance 153 b. In some embodiments, the third line ofweakness 125 b can be the same transverse length as the first line ofweakness 127 b, and/or the second line of weakness 123 b. The first andsecond lines of weakness 127 b, 123 b transversely overlap therespective secondary openings 129 b, 152 b and the third line ofweakness 125 b by a distance 141. Although as shown the overlap 141 isthe same for both the first line of weakness 127 b and the second lineof weakness 123 b, it is contemplated that the overlaps 141 can bedifferent relative to the different lines of weakness. The third line ofweakness 125 b can be any suitable line of weakness through the web 100allowing a user to hold onto the web or otherwise extend a hand, finger,tool, or similar feature through the web 100. For example, the thirdline of weakness 125 b can be a weaker line of weakness than the firstline of weakness 127 b and/or the second line of weakness 123 b. Forexample, as shown in FIG. 4, the third line of weakness 125 b is made ofperforations that are longer in length than the perforations that formthe first and second lines of weakness 125 b. The secondary openings 129b, 152 b can be any suitable opening through the web 100 allowing a userto hold onto the web or otherwise extend a hand, finger, tool, orsimilar feature through the web 100. For example, the secondary openingscan have transverse distances 169 b and longitudinal distances 167 b.For example, the secondary opening 129 b, 152 b can be a slit, aperforation, a rectangular or oval-shaped opening, or the like. As shownin FIG. 4, the secondary openings 129 b, 152 b can be transverselyoffset distances 159 b and 161 b from first longitudinal edge 110 and/orsecond longitudinal edge 112, respectively. The distances 151 b, 157 b,and 159 b can have different values with respect to one another. In someembodiments, two or more of the distances 151 b, 157 b, and 159 b can bethe same. For example, as shown in FIG. 4, the distances 151 b and 159 bare the same and are both smaller than the distance 157 b. The distances153 b, 155 b, and 161 b can have different values with respect to oneanother. In some embodiments, two or more of the distances 153 b, 155 b,and 161 b can be the same. For example, as shown in FIG. 4, thedistances 157 b and 161 b are the same and are both smaller than thedistance 155 b. In other embodiments, as shown for example in FIG. 15B,the distances 151 b and 157 b are the same and are both larger than thedistance 159 b. In other embodiments, as shown for example in FIG. 5,the distances 155 b and 153 b are the same and are both larger than thedistance 161 b. The secondary openings 129 b/152 b can be transverselyoriented apertures having a longer transverse distance 169 b than thelongitudinal distance 167 b. The longitudinal distance 169 b can begreater than the offset 133 b.

The embodiment shown in FIGS. 6 and 7A are similar to those of FIGS. 4and 5. In this embodiment, the tear initiation feature 128 can have oneor more secondary openings 129 c, 152 c, 158 c. In other embodimentssuch as shown in FIG. 7A, the tear propagation line 130 has only a firstline of weakness 127 c. The secondary openings 129 c, 152 c, 158 c canbe longitudinally offset from the first, and/or second lines of weakness127 c,123 c a distance 133 c, as shown for example in FIG. 7B.

The first line of weakness 127 c can be longitudinally offset from thesecond line of weakness 123 c and can be longitudinally offset from thesecondary openings 129 c, 152 c, 158 c a distance 133 c. The distances133 c are similar in scope to distances 133 b of FIG. 4. As shown inFIG. 6, the first line of weakness 127 c, and the second line ofweakness 123 c are co-linear. The secondary openings 129 c, 152 c, 158 ccan be any suitable opening through the web 100 allowing a user to holdonto the web or otherwise extend a hand, finger, tool, or similarfeature through the web 100. For example, the secondary opening 129 c,152 c, 158 c can be a slit, a perforation, a rectangular or oval-shapedopening, or the like. The secondary openings 129 c, 152 c, 158 c can betransversely offset distances 159 c, 161 c, and 163 c from firstlongitudinal edge 110. The first and second lines of weakness 127 c, 123c transversely overlap the respective secondary openings 129 c, 158 c bya distance 141. The secondary openings 129 c, 152 c, 158 c can be atransversely oriented aperture having a longer transverse distance 163 cthan the longitudinal distance 165 c. As shown in FIG. 7B, thelongitudinal distance 165 c is greater than the offset 133 c. Thesecondary openings 129 c, 152 c, 158 c can be transversely offset fromone another a distance 167 c.

In accordance with one embodiment, as shown in FIG. 8A, the inflatablechambers 120 can be separated by separation regions 126 d usable inconjunction with the web 100 of FIG. 1. As shown, the separation region126 d includes a tear initiation feature 128 and a tear propagation line130. The tear propagation line 130 includes a line of weakness 127 dextending transversely across a portion of the web 100. While the lineof weakness 127 d is shown as extending across the inflation channel114, denoted by the distance D in FIG. 1, it is appreciated that theline of weakness 127 d can also terminate with the seal 118 at orproximate seal end 124. The tear initiation feature 128 includes asecondary opening 129 d. The secondary opening 129 d can be any suitableopening through the web 100 allowing a user to hold onto the web orotherwise extend a hand, finger, tool, or similar feature through theweb 100. For example, the secondary opening 129 d can be a rectangularor oval-shaped opening (as shown for example in FIG. 8A), or the like.As shown in FIG. 8A, the ends of the secondary opening 129 d aresubstantially semi-circular. Such ends can enable a user to grasp anedge of the opening and pull on the web 100 thereby inducing a tear inthe tear propagation line 130, without the tear starting in the edge ofthe secondary opening. As shown in FIG. 8A, the secondary opening 129 dcan be a transverse aperture having both a significant longitudinaldistance 135 d and a significant transverse distance 139 d. Thelongitudinal distance 135 d can be greater than the width of the line ofweakness 127 d. The secondary opening 129 d can extend parallel to theline of weakness 127 d.

As shown in FIG. 8A, the line of weakness 127 d extends a distancelonger than the transverse distance 139 d of the secondary opening 129d. In other examples, the secondary opening 129 d is transversely offsetfrom the first longitudinal edge 110 a distance 151 d. Additionally oralternately, the secondary opening 129 d can be transversely offset fromthe second longitudinal edge 112 a distance 153 d. The line of weakness127 d can be longitudinally offset from the secondary opening 129 d adistance 133 d. In some examples, the distance 133 d is the same as orless than the connection distance between perforations in embodiments inwhich the line of weakness 127 d is a perforation (e.g., FIG. 8A showsthe line of weakness 127 d as a transverse perforation). In otherexamples, the distance 133 d is greater than the connection distancebetween perforations in embodiments in which the line of weakness 127 dis a perforation (e.g., the row of holes shown in FIG. 8A).

In accordance with one embodiment, as shown in FIG. 9, the inflatablechambers 120 can be separated by separation regions 126 e usable inconjunction with the web 100 of FIG. 1. The separation region 126 eincludes a tear initiation feature 128 and a tear propagation line 130.The tear propagation line 130 includes a line of weakness 127 eextending transversely across the web 100. While the line of weakness127 e is shown as extending across the inflation channel 114, denoted bythe distance Din FIG. 1, it is appreciated that the line of weakness 127e can also terminate with the seal 118 at or proximate seal end 124. Thetear initiation feature 128 includes a secondary opening 129 e. Thesecondary opening 129 e can be longitudinally offset from the line ofweakness 127 e a distance 133 e. In some examples, the distance 133 e isthe same as or less than the connection distance between perforations inembodiments in which the line of weakness 127 e is a perforation (e.g.,FIG. 9 shows the line of weakness 127 e as a transverse perforation). Inother examples, the distance 133 e is greater than the connectiondistance between perforations in embodiments in which the line ofweakness 127 e is a perforation.

As shown in FIG. 9, the line of weakness 127 e extends a distance longerthan the secondary opening 129 e. The secondary opening 129 e can be anysuitable opening through the web 100 allowing a user to hold onto theweb or otherwise extend a hand, finger, tool, or similar feature throughthe web 100. For example, the secondary opening 129 e can be an aperturehaving a shape that is generally a rectangle, circle, oval, or the like.As shown in FIG. 9, the secondary opening 129 e can be an aperturehaving a similar longitudinal distance 135 e and transverse distance 139e. The longitudinal distance 135 e can be greater than the offset 133 e.In some examples, the tear initiation feature 128 also includes alongitudinal appendage 131 e extending from the secondary opening 129 elongitudinally toward the line of weakness 127 e. Such an appendage 131e renders the secondary opening 129 e generally perpendicularly orientedrelative to the line of weakness 127 e. The appendage 131 e allows,enables or otherwise improves the ability of the secondary opening 129 eto tear toward the line of weakness 127 e when a user pulls on thesecondary opening 129 e, such as by providing a stress riser to initiatetearing. In some embodiments, the appendage 131 e is a cut from thesecondary opening 129 e. In other embodiments, the appendage 131 e is aline of perforation extending toward the line of weakness 127 e from thesecondary opening 129 e. Depending upon the position of the secondaryopening 129 e and the appendage 131 e, a pulling force on the secondaryopening 129 e can initiate a tear from a corresponding transverseposition along the line of weakness 127 e. For example, as shown in FIG.9, the secondary opening 129 e and appendage 131 e are positioned in agenerally central position relative to the line of weakness 127 e, suchthat a pulling force on the secondary opening 129 e can initiate a tearfrom a central portion of the line of weakness 127 e.

In accordance with one embodiment, as shown in FIG. 10, the inflatablechambers 120 can be separated by separation regions 126 f usable inconjunction with the web 100 of FIG. 1. The separation region 126 fincludes a tear initiation feature 128 and a tear propagation line 130.The tear propagation line 130 includes a line of weakness 127 fextending transversely across the web 100. While the line of weakness127 f is shown as extending across the inflation channel 114, denoted bythe distance Din FIG. 1, it is appreciated that the line of weakness 127f can also terminate with the seal 118 at or proximate seal end 124. Thetear initiation feature 128 includes a secondary opening 129 f and asecond secondary opening 152 f. The secondary opening 129 f can belongitudinally offset from the line of weakness 127 f a distance 133 f.In some examples, the distance 133 f is the same as or less than theconnection distance between perforations in embodiments in which theline of weakness 127 f is a perforation (e.g., FIG. 10 shows the line ofweakness 127 f as a transverse perforation). In other examples, thedistance 133 f is greater than the connection distance betweenperforations in embodiments in which the line of weakness 127 f is aperforation.

The secondary opening 129 f can be any suitable opening through the web100 allowing a user to hold onto the web or otherwise extend a hand,finger, tool, or similar feature through the web 100. For example, thesecondary opening 129 f can be an aperture having a shape that isgenerally a rectangle, circle, oval, or the like. As shown in FIG. 10,the secondary opening 129 f can be a longitudinally oriented aperturehaving a longer longitudinal distance 135 f than the transverse distance139 f. The longitudinal distance 135 f can be greater than the offset133 f. The longitudinal distance 135 f can be greater than the offset133 f. In this embodiment, the secondary opening 129 f extendsperpendicular to the line of weakness 127 f.

As shown in FIG. 10, the line of weakness 127 f extends a transversedistance longer than the transverse distance 139 f of the secondaryopening 129 f. In the embodiment shown in FIG. 10, there can be a secondsecondary opening 152 f in the tear initiation feature 128 on anopposing side of the line of weakness 127 f, such that the secondsecondary opening 152 f mirrors the secondary opening 129 f discussedabove (e.g., the second secondary opening 152 f has a substantiallysimilar shape, size, orientation, and longitudinal offset from the lineof weakness 127 f as the secondary opening 1290. The second secondaryopening 152 f can be longitudinally offset from the line of weakness 127f a distance 136 f. In some examples, the distance 136 f is the same orsubstantially the same distance as the distance 133 f. In this way,regardless of how the web 100 travels through an inflation machine, asecondary opening 129 f, 152 f will always be upstream of the lines ofweakness 127 f.

In accordance with one embodiment, as shown in FIG. 11, the inflatablechambers 120 can be separated by separation regions 126 g usable inconjunction with the web 100 of FIG. 1. The separation region 126 gincludes a tear initiation feature 128 and a tear propagation line 130.The tear propagation line 130 includes a line of weakness 127 gextending transversely across the web 100. While the line of weakness127 g is shown as extending across the inflation channel 114, denoted bythe distance Din FIG. 1, it is appreciated that the line of weakness 127g can also terminate with the seal 118 at or proximate seal end 124. Thetear initiation feature 128 includes a secondary opening 129 g. Thesecondary opening 129 g can be longitudinally offset from the line ofweakness 127 g a distance 133 g. In some embodiments, the distance 133 gis the same as or less than the connection distance between perforationsin embodiments in which the line of weakness 127 g is a perforation(e.g., FIG. 11 shows the line of weakness 127 g as a transverseperforation). In other examples, the distance 133 g is greater than theconnection distance between perforations in embodiments in which theline of weakness 127 g is a perforation.

As shown in FIG. 11, the line of weakness 127 g extends a distancelonger than the secondary opening 129 g. The secondary opening 129 g canbe any suitable opening through the web 100 allowing a user to hold ontothe web or otherwise extend a hand, finger, tool, or similar featurethrough the web 100. For example, the secondary opening 129 g can be aslit, a perforation, a rectangular or oval-shaped opening, or the like.As shown in FIG. 11, the secondary opening 129 g can be a transverselyoriented aperture having a longer transverse distance 139 g than thelongitudinal distance 135 g. The longitudinal distance 135 g can begreater than the offset 133 g. In some embodiments, the tear initiationfeature 128 also includes a longitudinal appendage 131 g extending fromthe secondary opening 129 g longitudinally toward the line of weakness127 g. Such an appendage 131 g allows, enables, or otherwise improvesthe ability of the secondary opening 129 g to tear toward the line ofweakness 127 g when a user pulls on the secondary opening 129 g. In someexamples, the appendage 131 g is a cut from the secondary opening 129 g.In other examples, the appendage 131 g is a line of perforationextending toward the line of weakness 127 g from the secondary opening129 g. Depending upon the position of the secondary opening 129 g andthe appendage 131 g, a pulling force on the secondary opening 129 g caninitiate a tear from a corresponding transverse position along the lineof weakness 127 g. For example, as shown in FIG. 11, the secondaryopening 129 g and appendage 131 g are positioned in a generally centralposition relative to the line of weakness 127 g, such that a pullingforce on the secondary opening 129 g can initiate a tear from a centralportion of the line of weakness 127 g.

FIG. 12A shows a partial schematic view of an embodiment of a stampingmachine 200 suitable for placing any of the lines of weakness disclosedinto a web 100. FIG. 12B shows an alternate, partial plan view of thestamping machine 200 of FIG. 12A. In the embodiment shown, the stampingmachine 200 includes a rolling drum 202 and a facing drum 204. Therolling drum 204 includes a dye 206. The dye 206 can include a firststamping element 210 and a second stamping element 212 separated by aspacer 211. The dye 206 can include more or fewer stamping elements andmore or fewer spacers, in accordance with the various embodiments ofseparation regions disclosed herein. In some embodiments, the stampingelements 210,212 are cutters 210,212. Cutters 210,212 can be thinelongate blades. In some embodiments, the spacer 211 is one or moreshims. In other embodiments, the spacer 211 can be integrally formedwith the rolling drum 202. In various embodiments, the spacer 211separates the stamping elements 210,212 by between 0.030 inches and0.090 inches, inclusive. In other embodiments, the spacer 211 separatesthe stamping elements 210,212 by between 0.015 inches and 0.120 inches,inclusive.

As shown in FIG. 12B, the stamping elements 210 and 212 can each have arespective plurality of cutting elements 213,215. In the embodimentshown, the cutting elements 213 are thin, linear edges spaced apart fromone another. Likewise, the cutting elements 215 are thin, linear edgesspaced apart from one another. The cutting elements 215 are each of asmaller length than the cutting element 213. This embodiment can beappropriate to form a separation region like 126 a of FIG. 2. Othertypes, shapes, numbers, and spacing between cutting elements 213 and 215are contemplated, in accordance with the various separation regionsdisclosed herein.

The facing drum includes a recess 208 corresponding to the dye 206. Therolling drum 202 and the facing drum 204 rotate in a synchronizedfashion. For example, the rolling drum 202 can rotate in a direction201, and the facing drum 204 can rotate in a direction 203, such that asthe web 100 passes between the drums 202,204 the dye 206 and the recess208 periodically come together, and the dye 206 punctures one or bothplies 105,107 of the web 100 to impart separation regions 126, includinglines of weakness, to the plies 105,107 of the web 100. The dye 206 canbe at least partially received within the recess 208. The diameters ofthe drums 202,204 can be varied to change the spacing between successiveseparation regions 126 disposed along the web 100 between adjacentchambers 120. The rotation of the drums 202,204 can be synchronized withany suitable mechanism, such as mating gears, a synchronization ortiming belt or chain and corresponding sprockets.

As shown in FIG. 12A, the rolling drum 202 includes three sets of dyes206, and the backing drum 204 includes three corresponding recesses 208.A web 100 passes between the drums 202 and 204, over an idler 220, andis taken up by a take-up roll 218. Other numbers of dyes and recesses,are contemplated to correspond to different webs 100. In the embodimentshown in FIG. 25A, the stamping machine is configured to place aseparation region 126 within alternating seals 118. Other embodimentscan place separation regions in each of the transverse seal regions.Other embodiments still can place separation regions in seals, skippingdifferent numbers of transverse seals 118. For example, a stampingmachine can place separation regions in every third, fourth, fifth, orsixth seal. In other embodiments, a stamping machine 200 can place aseparation region in a seal 118 and skip two or more seals beforeplacing another separation region 126.

FIG. 13 shows a partial schematic view of another embodiment of astamping machine 200. In this embodiment, the machine 200 includes areciprocating element 214 that reciprocates back and forth relative to abacking element 216, as shown by directional arrows 209. In variousembodiments, the reciprocating element 214 can include a dye 206, or arecess 208. In various other embodiments, the backing element 216 caninclude a dye 206, or a recess 208. As shown, the reciprocating element209 reciprocates back and forth as the web 100 passes between thereciprocating element 214 and the backing element 216. As thereciprocating element 214 moves down toward the backing element, the dye206 punctures one or both plies 105,107 of the web 100 to impartseparation regions 126, including lines of weakness, to the plies105,107 of the web 100. The dye 206 can be at least partially receivedwithin the recess 208.

In various embodiments, the distances 133 and 136 are less than 50 mils.In other embodiments, the distances 133 and 136 are from 10-20 mils.

Any of the various separation regions 126 a-g discussed in theembodiments above can be disposed along the longitudinal extent of thefilm 100 and extend transversely across the first and second plies ofthe film 100. Each separation region 126 a-g extends from the secondlongitudinal edge 112 and toward the first longitudinal edge 110, alongat least a portion of the transverse width of the film 100. Eachseparation region 126 in the web 100 is disposed between a pair ofadjacent chambers 120. Preferably, each line of weakness is disposedbetween two adjacent transverse seals 118 and between two adjacentchambers 120, as depicted in FIG. 1. In other embodiments, the lines ofweakness are disposed in a wide seal as shown in FIGS. 2-11. Theseparation regions 126 facilitate separation of adjacent inflatablecushions 120.

While the secondary openings 129 e, 129 g of FIGS. 9, 11 are the onlyembodiments depicted with longitudinal appendages 131 e, 131 g,respectively, it is contemplated that one or more longitudinalappendages can be included with a secondary opening of any embodiment.The appendage can be a slit or line of perforation extendinglongitudinally toward a line of weakness from the secondary opening. Inother embodiments, an appendage can extend diagonally across the web100, extending both longitudinally and transversely. In the same manneras discussed above with respect to FIGS. 9 and 11, the appendage allows,enables or otherwise improves the ability of the secondary opening totear toward the line of weakness when a user pulls on the secondaryopening. Depending upon the position of the secondary opening and theappendage, a pulling force on the secondary opening can initiate a tearfrom a corresponding transverse position along the line of weakness. Forexample, in some embodiments, the appendage can extend toward a centralportion of the line of weakness. In this manner, a pulling force on thesecondary opening can create a tear of the transverse line of weaknessthat initiates in the central portion of the transverse line ofweakness.

While the separation regions 126 disclosed are within the transverseseal 118 (e.g., as shown in FIG. 1), it is contemplated that one or moreof the separation regions 126 can be outside the transverse seal 118,for example, within another adjacent seal (not shown) positionedadjacent the transverse seal 118. The adjacent seal can be positionedwithin the inflatable chamber 120, forming a sealed portion of the airchamber 120. The adjacent seal can extend along only a portion of thetransverse width of the film 100 or across the entire transverse widthof the film 100 parallel to the transverse seal 118. It is contemplatedthat a transverse line of weakness can be included within the transverseseal 118, while a corresponding secondary opening can be included withinan adjacent seal, outside of and adjacent to the transverse seal 118.The adjacent seal can have a shape and size sufficient to surround thesecondary opening while providing minimum interference to fluid such asair filling the chamber 120.

Alternatively, as previously discussed, it is contemplated that thetransverse seal 118 can have sealed portions around its periphery with apocket in the middle portion. In this example, a transverse line ofweakness can be located in a sealed portion of the transverse seal 118,while a respective secondary opening can be included in an opposingsealed portion of the transverse seal 118. In this manner, a transverseline of weakness is in a separate sealed portion from a respectivesecondary opening.

In the examples where there is either more than one transverse line ofweakness (e.g., transverse lines of weakness 125 a, 127 a in FIG. 2) ormore than one secondary opening (e.g., secondary openings 129 b, 152 bin FIG. 4), two of the separation regions 126 can be included in oneseal (e.g., the transverse seal 118) or sealed portion (e.g., a sealededge of the transverse seal 118), while the remaining separation regioncan be included in another seal (e.g., the adjacent seal) or sealedportion (e.g., the opposing sealed edge of the transverse seal 118). Forexample, in FIG. 6, the secondary opening 152 c and transverse line ofweakness 127 c can be included in the transverse seal 118 or in a sealededge of the transverse seal 118, while the respective secondary opening129 c is included in a separate seal positioned within the inflatablechamber 120 adjacent the transverse seal 118 or within a sealed opposingedge of the transverse seal 118. In another example, the transverse seal118 can have an additional distinct seal or sealed portion that includesthe additional tear initiation feature 128, such that each tearinitiation feature 128 is included in a different seal or sealed portionof the transverse seal 118. As one example, the transverse seal 118 hasa sealed middle portion that includes the transverse line of weakness125 a, separate from respective transverse lines of weakness 127 a whichis included within sealed opposing edge portions of the transverse seal118. As another example, the transverse seal 118 has a sealed middleportion that includes transverse lines of weakness 125 e, 127 e,separate from a respective secondary opening 129 e, which is includedwithin sealed opposing edge portions of the transverse seal 118. Asanother example, a transverse line of weakness 127 a is included withinthe transverse seal 118, while the transverse line of weakness 125 a ispositioned within separate seals. As another example, transverse line ofweakness 125 e, 127 e are included within the transverse seal 118, whilethe secondary opening 129 e is positioned within separate seals.

The transverse lines of weakness can include a variety of lines ofweakness known by those of ordinary skill in the art. For example, insome embodiments, the transverse lines of weakness include a row ofperforations, in which the row of perforations includes alternatinglands and slits spaced along the transverse extent of the row. The landsand slits can occur at regular or irregular intervals along thetransverse extent of the row. Alternatively, for example, in someembodiments, the transverse lines of weakness include score lines or thelike formed in the web material.

The transverse lines of weakness and/or secondary openings can be formedfrom a variety of techniques known to those of ordinary skill in theart. Such techniques include, but are not limited to, cutting (e.g.,techniques that use a cutting or toothed element, such as a bar, blade,block, roller, wheel, or the like) and/or scoring (e.g., techniques thatreduce the strength or thickness of material in the first and secondplies, such as electromagnetic (e.g., laser) scoring and mechanicalscoring).

This application is also copending with patent application Ser. No.16/541,082 filed 14 Aug. 2019, entitled “Inflatable Packaging with TearInitiation Feature”, which is hereby incorporated by reference herein inits entirety for all purposes. Consistent with the disclosure thereinand as a person of ordinary skill in the art would understand theseapplications, the various embodiments of the separation region disclosedin the copending application can be incorporated herein.

FIG. 14 illustrates an example of an inflatable packaging sealing device300 for use in sealing the inflatable flexible structures. The inflationand sealing device 300 may be operated to convert a flexible structure100 of uninflated material 302 into a series of inflated pillows orcushions 303 by inflating chambers 120. As shown in FIG. 14, theuninflated flexible structure 100 can be a bulk quantity of supply,uninflated material. For example, uninflated flexible structure 100 maybe provided in bulk form on a roll to be inflated and sealed by thedevice 300. For example, the bulk quantity of uninflated material may bea roll of the material 334. The flexible structure 100 may be rolledaround an inner support tube 333. Although, in other examples, the bulkquantity may be packaged in other suitable forms such as fanfold.

The inflation and sealing device 300 may include a bulk material support336. The bulk quantity of uninflated material may be supported by thebulk material support 336. For example, in embodiments incorporating aroll of bulk material, the bulk material support may include a singleroller that accommodates the center of the roll of web material 334. Theroll of the material 334 may be suspended over the bulk material support336, such as a spindle passing through the core 333 of the roll of thematerial 334. In another example, the bulk material support may be atray operable to hold the uninflated material, which can be provided bya fixed surface or a plurality of rollers, for example. The tray may beconcave around the roll or the tray may convex with the roll suspendedover the tray. The bulk material support may include multiple rollers,which suspend the web. In various embodiments, the roll core is made ofcardboard or other suitable materials.

In accordance with various embodiments, the inflation and sealing device300 includes a fluid dispensing mechanism. As shown in the example ofFIG. 14, the fluid dispensing mechanism is a nozzle 340. In otherembodiments, the fluid dispensing mechanism can be other anothersuitable device configured to inject air into chambers 120 such as awide vent, channel, manifold or the like. In emblements having a nozzle,the nozzle 340 is configured to inflate the uninflated material 302forming inflated pillows or cushions 303 by inflating chambers 120. Forexample, the nozzle 340 engages an inflation region located at anytransverse distance between the longitudinal edges. As shown in theexample of FIG. 14 and in the various embodiments of the web discussedabove, the inflation region is a channel 114 extending longitudinallyalong the length of the flexible structure 100 proximal to one edge. Inthe example shown in FIG. 14, the web 100 can roll off of materialsupport 336 and over guide 338 in a manner that aligns the channel 114of the flexible structure 100 with the nozzle 340 in inflation area 342.The inflation and sealing device 300 may be configured for continuousinflation of the flexible structure 100, as it is unraveled from theroll 334. The roll 334 includes the plurality of inflation chambers 120that are arranged in series. The flexible structure 100 is advanced overthe inflation nozzle 340 with the chambers 120 extending transverselywith respect to the inflation nozzle 340 and an outlet on the inflationnozzle. The outlet, which can be disposed on a radial side and/or theupstream tip of the nozzle, for example, directs fluid from a nozzlebody into the chambers 120 to inflate the chambers 120 as the flexiblestructure 100 advances along the material path in a longitudinaldirection. The inflated flexible structure 100 is then sealed by asealing mechanism in the sealing area 374 to form a chain of inflatedpillows or cushions.

In other embodiments, the channel can be a central channel with chamberson both transverse sides of the inflation channel. In other embodiments,the inflation region can be an open passage along the longitudinallength of one edge of the flexible structure. For example, one edge ofthe flexible structure can have unattached plies of material. The Fluiddispensing mechanism (e.g. vent, channel, manifold, nozzle, etc.) candispensing fluid between the plies as they are separated, inflating thechambers.

The inflation nozzle inserts fluid, such as pressured air, along a fluidpath into the uninflated web material through nozzle outlets, inflatingthe material into inflated pillows or chambers 120. The inflation nozzlecan include a nozzle inflation channel that fluidly connects a fluidsource with the nozzle outlets. It is appreciated that in otherconfigurations, the fluid can be other suitable pressured gas, foam, orliquid. The flexible structure 100 is fed over the inflation nozzle,which directs the web to the inflation and sealing assembly 308. Theflexible structure 100 is advanced or driven through the inflation andsealing device 300 by a drive mechanism, such as by a driver or sealingdevice or the drive roller, in a downstream direction along a materialpath.

After being fed through the web feed area 364, the first and secondplies are sealed together by the sealing assembly and exit the sealingdevice. The sealing device may include heating elements, such asthermocouples, which melt, fuse, join, bind, or unite the two plies orother types of welding or sealing elements. The web 100 is continuouslyadvanced through the sealing assembly along the material path and pastthe sealing device at a sealing area 374 to form a continuouslongitudinal seal 305 along the web by sealing the first and secondplies together, and exits the sealing area. In various embodiments, theinflation and sealing device 300 further includes a cutting assembly tocut the web off the inflation nozzle when an inflation channel thatreceives and is closed around a longitudinal inflation nozzle is used.

In accordance with various embodiments, the inflation and sealing devicecan have any suitable drive mechanism for advancing the flexiblestructure 100 through the inflation and sealing device 300. For example,one belt may drive the various rollers and a second belt may pinch theweb against a sealing device such as a drum. In various embodiments, theinflation and sealing device may have no belts. For example, a sealingdrum may pinch the web against a stationary platform and drive the webthorough the inflation and sealing device at the same time. In anotherexample, rollers may advance the flexible structure 100 through theinflation and sealing device 300.

Examples of components that may be utilized within an inflation andsealing device 300, including without limitation, the nozzle, blower,sealing assembly, and drive mechanisms, and their various components orrelated systems may be structured, positioned, and operated as disclosedin any of the various embodiments described in the incorporatedreferences such as, for example, U.S. Pat. Nos. 8,061,110; 8,128,770;U.S. Patent Publication No. 2014/0261752; and U.S. Patent PublicationNo. 2011/0172072 each of which is herein incorporated by reference. Eachof the embodiments discussed herein may be incorporated and used withthe various sealing devices of the incorporated references and/or otherinflation and sealing devices. For example, suitable mechanismsdiscussed herein and/or in the incorporated references may be used inthe inflation and sealing of flexible structure 100.

The present disclosure is not to be limited in terms of the particularexamples described in this application, which are intended asillustrations of various aspects. Many modifications and examples can bemade without departing from its spirit and scope, as will be apparent tothose skilled in the art. Functionally equivalent methods andapparatuses within the scope of the disclosure, in addition to thoseenumerated herein, will be apparent to those skilled in the art from theforegoing descriptions. Such modifications and examples are intended tofall within the scope of the appended claims. The present disclosure isto be limited only by the terms of the appended claims, along with thefull scope of equivalents to which such claims are entitled. It is to beunderstood that this disclosure is not limited to particular methods,reagents, compounds compositions or biological systems, which can vary.It is also to be understood that the terminology used herein is fordescribing particular examples only, and is not intended to be limiting.

With respect to the use of substantially any plural and/or singularterms herein, those having skill in the art can translate from theplural to the singular and/or from the singular to the plural as isappropriate to the context and/or application. The varioussingular/plural permutations may be expressly set forth herein for sakeof clarity.

It will be understood by those within the art that, in general, termsused herein, and especially in the appended claims (e.g., bodies of theappended claims) are generally intended as “open” terms (e.g., the term“including” should be interpreted as “including but not limited to,” theterm “having” should be interpreted as “having at least,” the term“includes” should be interpreted as “includes but is not limited to,”etc.).

It will be further understood by those within the art that if a specificnumber of an introduced claim recitation is intended, such an intentwill be explicitly recited in the claim, and in the absence of suchrecitation, no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to examples containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should be interpreted to mean “at least one”or “one or more”); the same holds true for the use of definite articlesused to introduce claim recitations. In addition, even if a specificnumber of an introduced claim recitation is explicitly recited, thoseskilled in the art will recognize that such recitation should beinterpreted to mean at least the recited number (e.g., the barerecitation of “two recitations,” without other modifiers, means at leasttwo recitations, or two or more recitations).

Furthermore, in those instances where a convention analogous to “atleast one of A, B, and C, etc.” is used, in general such a constructionis intended in the sense one having skill in the art would understandthe convention (e.g., “a system having at least one of A, B, and C”would include but not be limited to systems that have A alone, B alone,C alone, A and B together, A and C together, B and C together, and/or A,B, and C together, etc.). In those instances where a conventionanalogous to “at least one of A, B, or C, etc.” is used, in general sucha construction is intended in the sense one having skill in the artwould understand the convention (e.g., “a system having at least one ofA, B, or C” would include but not be limited to systems that have Aalone, B alone, C alone, A and B together, A and C together, B and Ctogether, and/or A, B, and C together, etc.). It will be furtherunderstood by those within the art that virtually any disjunctive wordand/or phrase presenting two or more alternative terms, whether in thedescription, claims, or drawings, should be understood to contemplatethe possibilities of including one of the terms, either of the terms, orboth terms. For example, the phrase “A or B” will be understood toinclude the possibilities of “A” or “B” or “A and B.”

As will be understood by one skilled in the art, for any and allpurposes, such as in terms of providing a written description, allranges disclosed herein also encompass any and all possible subrangesand combinations of subranges thereof. Any listed range can be easilyrecognized as sufficiently describing and enabling the same range beingbroken down into at least equal halves, thirds, quarters, fifths,tenths, etc. As a non-limiting example, each range discussed herein canbe readily broken down into a lower third, middle third and upper third,etc. As will also be understood by one skilled in the art all languagesuch as “up to,” “at least,” “greater than,” “less than,” and the likeinclude the number recited and refer to ranges which can be subsequentlybroken down into subranges as discussed above. Finally, as will beunderstood by one skilled in the art, a range includes each individualmember. Thus, for example, a group having 1-3 items refers to groupshaving 1, 2, or 3 items. Similarly, a group having 1-5 items refers togroups having 1, 2, 3, 4, or 5 items, and so forth.

As will be understood by one skilled in the art, for any and allpurposes, all references to order, (e.g., first, second, third), areonly used for identification purposes to aid the reader's understandingof the present invention, and do not create limitations, particularly asto the position, orientation, or use of the invention. Such recitationsof order do not limit the scope of disclosure in any way, and elementsmay be claimed with such references in any order without departing fromthe present disclosure.

While various aspects and examples have been disclosed herein, otheraspects and examples will be apparent to those skilled in the art. Thevarious aspects and examples disclosed herein are for purposes ofillustration and are not intended to be limiting, with the true scopeand spirit being indicated by the following claims.

What is claimed is:
 1. An inflatable web, comprising: a first film ply;and a second film ply sealed to the first ply via a plurality ofgenerally transverse seals to define a first and second inflatablechambers therebetween and an inflation region, the chambers beinginflatable with a fluid and operable to contain the fluid, the sealedplies having a first longitudinal edge and a second longitudinal edge;wherein the web defines a separation region extending at least partiallytransversely across the web between the first inflatable chamber and theinflatable second chamber, the separation region being configured tofacilitate separation of the first and second inflatable chambers,wherein the separation region includes: a tear propagation lineextending transversally across at least a portion of the web with an endof the tear propagation line terminating proximal to the firstlongitudinal edge of the web or the inflation region, and a tearinitiation feature including edges spaced apart from one anotherlongitudinally to form a permanent opening in the web, and close enoughto the tear propagation line that a force imparted to the web via thetear initiation feature will facilitate the initiation of a tear of theweb such that the tear propagates to an end of the tear propagation lineand allowing for the tearing of the web to separate the first inflatablechamber from the second inflatable chamber.
 2. The web of claim 1,wherein the tear propagation line includes a first line of weaknessextending transversely across a portion of the web.
 3. The web of claim2, wherein the tear initiation feature is configured to facilitate theengagement between a user and the web for tearing.
 4. The web of claim3, wherein the tear initiation feature is suitable for a user to graspthe web by extending one of a hand, finger, or tool, through the web. 5.The web of claim 4, wherein the tear propagation line includes a secondline of weakness extending transversely across at least a portion of theweb with an end of the second line of weakness line terminating proximalto the second longitudinal edge of the web.
 6. The web of claim 5,wherein the tear initiation feature is disposed between respective endsof the first line of weakness and the second line of weakness.
 7. Theweb of claim 6, wherein respective lands are disposed between respectiveends of the tear initiation feature and the first and second lines ofweakness.
 8. The web of claim 5, wherein the first line of weaknessincludes a line of perforations through at least one of the first ply orsecond ply.
 9. The web of claim 8, wherein the second line of weaknessincludes a line of perforations through at least one of the first ply orsecond ply.
 10. The web of claim 6, wherein the tear initiation featureis transversely offset from both the first and second longitudinaledges.
 11. The web of claim 10, wherein the tear initiation feature isin a generally central position relative to the transverse width of theweb.
 12. The web of claim 6, wherein the tear propagation line and thetear initiation feature are sufficiently close that a tear initiated inthe tear initiation feature propagates to the tear propagation line. 13.The web of claim 2, wherein the first line of weakness extendstransversely across the web from the first longitudinal edge to thesecond longitudinal edge.
 14. The web of claim 6, wherein the tearinitiation feature is longitudinally offset from the tear propagationline.
 15. The web of claim 14, wherein the tear initiation featureincludes a pair of openings through the web and the openings aretransversely offset from one another.
 16. The web of claim 15, whereinthe tear initiation feature includes a third line of weakness extendingtransversely across a portion of the web, and the third line of weaknessis longitudinally offset from the pair of openings.
 17. The web of claim16, wherein the perforations of the third line of weakness aretransversely larger than the perforations of the first line of weaknessand the second line of weakness.